Design Guideline For Hydraulic Fluid Cleanliness

x
= ?
x
= ?
Design Guideline
for Hydraulic Fluid
Cleanliness
Technical
Information
100
75
50
10
10 20
5
0.5 1 5
10
-
v
a
lu
e
Differential pressure (bar)
P001 322E
13 m
d = 13 m
Square 78.5 m
2
d = 10 m
Old: New:
P001 935E

78.5 m
2
4
d = = 10 m

2 520L0467 Rev GC Feb 2008

Design Guideline for Hydraulic Fluid Cleanliness
Technical Information
This leaet is intended to assist the designer of an installation, a set or a hydrostatic
drive to ensure that the requirement for a specic minimum cleanliness of the hydraulic
uid is met by means of design measures such as the selection of an optimal lter, or
preferably of an economically efcient ltration concept. This includes start-up, operation
and topping up of hydraulic uid.
In hydrostatic systems a series of sliding surfaces act as hydrostatic-hydrodynamic
bearings with gap heights in the range of 10 m. That is why dirt is the greatest enemy of
hydraulic systems, since depending on its nature and composition it generates wear and
thus shortens service lives.
This is true for all elds of mechanical engineering and it cannot be repeated often
enough. At the present time it is not possible to predict the length of the service life of a
hydrostatic unit as a function of the cleanliness of the hydraulic uid. The fact that these
constraints are not known for roller bearings either, even though very many parameters
have been researched for these parts in particular, shows just how complicated these
wear mechanisms are.
Although more effort is currently being concentrated on trying to measure dirt
sensitivity of hydrostatic units in short-term contamination tests, such experiments are
unsuccessful because contamination sensitivity cannot be measured like pressures or
speeds. The leading manufacturers of hydrostatic equipment have therefore decided
to give priority to investigating the fundamentals of wear caused by contamination in
hydrostatic units within the framework of a joint research project.
It is uncertain to what extent service life prognoses will be possible at the end of the
research project, if at all. It can, however, be stated that the cleaner a system, the higher
its service life expectancy.
A satisfactory service life is achieved if the cleanliness level as required below is
maintained.
Initial Questions and Answers
PURPOSE OF THIS
LEAFLET
WHY IS FILTRATION
NECESSARY?
2008, Sauer-Danfoss. All rights reserved. Printed in Europe.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Front cover illustrations: P001 317 and P001 322E.
3 520L0467 Rev GC Feb 2008
Contents
Purpose of this leaet ................................................................................................................................... 2
Why is ltration necessary? ......................................................................................................................... 2
Where does the dirt come from? .............................................................................................................. 4
How can the required cleanliness level be achieved? ...................................................................... 4
Assembly dirt.............................................................................................................................................. 4
Operating dirt ............................................................................................................................................ 4
Denition of -ratio, efciency, lter neness ..................................................................................... 6
Cleanliness features ....................................................................................................................................... 8
Denition of cleanliness levels per ISO 4406 .................................................................................. 8
New particle size denition .................................................................................................................10
Recommendation for lter neness / retaining rates (Beta-ratios) ......................................10
Technical .........................................................................................................................................................11
Requirements of hydraulic uids ............................................................................................................11
Fluid cleanliness requirements ..........................................................................................................11
Closed circuit .................................................................................................................................................13
Design of a lter in the suction line .................................................................................................13
Design of a lter in the charge circuit .............................................................................................13
Open circuit ....................................................................................................................................................14
Design of a lter in the suction line .................................................................................................14
Design of a lter in the return line ....................................................................................................14
Filtration in circuits with multiple pumps ......................................................................................14
Recommendations for differential pressure (pressure drop) of a new lter element
and -ratios for closed and open circuit .........................................................................................14
Dirt absorption capacity, maximum differential pressure ........................................................15
Why a bypass? ...............................................................................................................................................16
Contamination indicator ...........................................................................................................................17
What is to be done if the required cleanliness class is not achieved? .......................................18
Why loop ushing? ......................................................................................................................................18
Taking of uid samples ...............................................................................................................................19
Sampling according to ISO 4021 from a system in operation .....................................................19
Sampling device ......................................................................................................................................19
Sampling method ...................................................................................................................................19
Sampling from a tank according to CETOP RP 95 H ..................................................................20
Working hints.................................................................................................................................................21
Scavenging and running in .................................................................................................................21
Monitoring of contamination ..................................................................................................................22
Permanent .................................................................................................................................................22
Cyclical ........................................................................................................................................................22
Topping up hydraulic uid ..................................................................................................................22
Changing the element ..........................................................................................................................23
INITIAL QUESTIONS AND
ANSWERS
REQUIRED FLUID
CLEANLINESS
SELECTION OF AN
APPROPRIATE FILTER
AND FILTRATION SYSTEM
TAKING OF FLUID
SAMPLES
WORKING HINTS
4 520L0467 Rev GC Feb 2008
WHERE DOES THE DIRT
COME FROM?
HOW CAN THE REQUIRED
CLEANLINESS LEVEL BE
ACHIEVED?
We distinguish between two essential sources of dirt:
contamination occurring during assembly assembly dirt
contamination occurring during operation operating dirt
Assembly dirt
Different kinds of dirt occur during the various production operations: chips, moulding
sand, core residues, cleaning-rag lint, welding beads, scale etc. Products supplied by
Sauer-Danfoss are therefore cleaned in modern cleaning installations after completion of
machining operations on the individual parts. Careful attention is also paid to cleanliness
when these clean individual parts are assembled to form highgrade hydrostatic units.
However, since dirt occurs during the nal assembly in a vehicle, of a set etc., especially
during the piping work, it is advisable to ush the whole system prior to commissioning.
The basic contamination of the clean hydraulic uid supplied must also be added to
the assembly dirt. As investigations have shown, new hydraulic uid can contain basic
dirt levels in excess of the cleanliness level admissible for optimum operation
(see section Cleanliness requirements, page 11). That is why a system should always be
lled up via a lter assembly. Particles of the same order of magnitude as the gap widths
are to be considered as especially critical.
Operating dirt
Fine dirt from the surrounding environment is drawn into the hydraulic system during
operation via piston rods or other moving seals. Abrasive particles from the components
are also pumped through the system with the uid. A frequently underestimated source
of contamination is from unsuitable venting facilities of uid tanks. Fluctuations in
volume cause ne dust to be drawn into the tanks, from where it causes abrasion of the
sliding combinations in the system.
A ltration system must be designed in such a way that it is able to retain the new dirt
entering the overall system in the lter in order to maintain the required cleanliness level
throughout the whole operating life.
An example of this is described below:
If a lter is used in the suction line or the charge circuit, the charge pump size selected
- in our example 17 cm
3
- determines the volume ow available for ltering as a function
of the speed. The following theoretical calculation serves to illustrate this (see illustration
P001 318, page 5).
Assuming that the pump runs at a nominal speed of 1500 min
-1
, then at an assumed
volumetric efciency of 90 %, a charge pump volume ow of approx. 23 l/min results.
A contamination level of 230 particles larger than 10 m/ml has developed in the oil tank
and a lter with
35
= 75,
10
= 2 (= 50 % ltration efciency, see table below) is tted in the
suction line. The contamination is also distributed uniformly in the uid. Approximately
5.3 x 10
6
particles larger than 10 m per minute are now drawn from the tank with the
charge pump ow. The lter element holds back 50 % of the particles larger than 10 m,
so that 2.65 x 10
6
particles larger than 10 m reach the charge pump each minute.
5 520L0467 Rev GC Feb 2008
HOW CAN THE REQUIRED
CLEANLINESS LEVEL BE
ACHIEVED?
(continued)
If 2.65 x 10
6
particles larger than 10 m are also passed to the system per minute (via
ventilation lters, piston rods or abrasion), there is no change in the cleanliness level.
If fewer than 2.65 x 10
6
particles larger than 10 m are passed to the system, a lower i. e. a
better cleanliness level is achieved. However if more than 2.65 x 10
6
particles larger than
10 m are passed to the system, a higher i. e. a worse cleanliness level is achieved.
As mentioned at the beginning, this calculation is very close to conditions encountered
in practice, but these will never be so exact because particles will settle at the bottom of
the tank in areas with a low ow velocity. Nor are the particles so uniformly distributed
when they pass through the lter. This example is merely intended to illustrate the
principle and it can be established that:
The cleanliness level is improved if:
the lter neness is improved
(higher -value for a certain particle size, i. e.
10
= 2 becomes
10
= 2.5)
the volume ow* via the lter is increased
The cleanliness level deteriorates if:
the lter neness deteriorates
(lower -value for a certain particle size, i. e.
10
= 2 becomes
10
= 1.8)
the volume ow* via the lter is reduced
The ow volume cannot generally be selected freely since it is determined in a closed
circuit by the size of the charge pump. However other operating factors take priority
when the charge pump size is selected. In these cases, therefore, the -value must be
varied. However, if the -value is increased (different lter material) without the structural
dimensions of the lter being increased, then the consequence is that:
the differential pressure rises (applies for new, uncontaminated lter element)
the dirt absorption capacity drops (reduced service life)
Schematic Series 90 variable pump with suction lter
P001 318E
2.65 x 10
6
particles > 10 m/min
35
= 75 (
10
= 2 equivalent 50 %)
Q = 23 l/min
5.3 x 10
6
particles > 10 m/min
230 particles > 10 m/ml
L2 S
S
e
rv
o
M
A
B
L1
* Note the change of the
-value shown on page 15,
diagram P001 322E.
The alteration of the
volume ow also changes
the differential pressure
and hence the value too.
However the volume ow
has more inuence on the
cleanliness level.
6 520L0467 Rev GC Feb 2008
The -ratio is dened and determined in ISO 16 889-1999 Multi-pass test
(old: ISO 4572-1982) as:

Number of particles > x m upstream of the lter
X
=

Number of particles > x m downstream of the lter
As a characteristic number the
10
-ratio is to be specied.
Example:

500 particles > 10 mm upstream of the lter
10
= = 50

10 particles > 10 mm downstream of the lter
This number denes the ratio of the number of particles before and after the lter. This
means from 500 particles larger than 10 m before the lter, 490 particles are retained
in the element and only 10 pass through or from 50 particles before the lter, 49 are
retained and only 1 passes through. This can be expressed as lter efciency:

500 - 10 50 - 1
Filter efciency = = = 98 %

500 50
or:

1 1
Filter efciency = 1 - = 1 - = 98 %

10
50
This efciency makes the lter performance more understandable. Table below shows
clearly the relationship between -ratio and efciency. In practice the following term is
often used:
X
= 75 (= 98,67 % efciency)
The observant reader will notice that increasing the -ratio by 50 % (from 50 to 75) the
efciency only increases by 0.67 %, therefore
X
-ratios above 75 % are not reasonable.
In some lter manufacturers catalogues you sometimes nd
X
larger than 2000.
The real efciency increase is shown in the table on page 7. The
10
= 75-ratio has been
established as a standard. This species the particle size (indicated as
X
) were the -ratio
is equal to 75. This particle size is used to classify the lter neness.

Example:
35
= 75 equals a lter neness of 35 m
The term absolute lter neness may not be used for this.
Together with the -ratio the related differential pressure at the lter element has to be
specied. Unfortunately this is not always specied in the lter manufacturers catalogue.
DEFINITION OF -RATIO,
EFFICIENCY, FILTER
FINENESS
7 520L0467 Rev GC Feb 2008
DEFINITION OF -RATIO,
EFFICIENCY, FILTER FINE-
NESS (continued)
-ratio efciency -ratio efciency
1.0 0.0 6.4 84.4
1.1 9.1 6.8 85.3
1.2 16.7 7.0 85.7
1.3 23.1 7.2 86.1
1.4 28.6 7.4 86.5
1.5 33.3 7.6 86.8
1.6 37.5 7.8 87.2
1.7 41.1 8.0 87.5
1.8 44.5 8.2 87.8
1.9 47.3 8.4 88.1
2.0 50.0 8.6 88.4
2.1 52.4 8.8 88.6
2.2 54.4 9.0 88.9
2.3 56.5 9.2 89.1
2.4 58.3 9.4 89.4
2.5 60.0 9.6 89.6
2.6 61.5 9.8 89.8
2.7 62.9 10 90.0
2.8 64.3 11 90.9
2.9 65.5 12 91.6
3.0 66.6 13 92.3
3.1 67.7 14 92.9
3.2 68.8 15 93.3
3.3 69.7 16 93.8
3.4 70.6 17 94.1
3.5 71.4 18 94.4
3.6 72.2 19 94.5
3.7 72.9 20 95.0
3.8 73.7 30 96.7
3.9 74.4 40 97.5
4.0 75.0 50 98.0
4.2 76.2 60 98.3
4.4 77.3 70 98.6
4.6 78.3 75 98.67
4.8 79.2 80 98.7
5.0 80.0 90 98.9
5.2 80.8 100 99.0
5.4 81.5 200 99.5
5.6 82.1 500 99.8
5.8 82.8 1000 99.9
6.0 83.3 2000 99.95
6.2 83.8
-ratio versus efciency
8 520L0467 Rev GC Feb 2008
The old ISO 4406-1987 denes the cleanliness level of particles larger than 5 m and
15 m. As an example: if 1910 particles/ml larger than 5 m and 71 particles/ml larger
than 15 m are counted, the ISO 4406-1987 code level is 18/13.
In 1999 both, the denition for particle counting and the denition of ISO code was
changed. The required cleanliness class denition is now determined by ISO 4406-1999.
The allocated particle sizes are:
Comparison of old and new standard ISO 4406
Please note, that (c) must be added to the new denition in order to identify that it is
the new ISO 4406. The old method for particle counting may still be used.
The ISO 4406-1999 cleanliness class 22/18/13 means:
22 species the number of particles larger than 4 m (c),
18 species the number of particles larger than 6 m (c), and
13 species the number of particles larger than 14 m (c) related to 1 ml respectively
100 ml of the inspected uid.
CLEANLINESS FEATURES
d e n i f e d t o n ) c ( m 4
m 5 ) c ( m 6
m 5 1 ) c ( m 4 1
Old ISO 4406-1987 New ISO 4406-1999
Required Fluid Cleanliness
Denition of cleanliness levels per ISO 4406
The cleanliness level of a hydraulic uid is determined by counting number and size of
particles in the uid. The number of particles is dened as a cleanliness level according to
ISO 4406.
Denition of cleanliness levels per ISO 4406
Number of particles per 100 ml Number of particles per 1 ml Cleanliness levels per ISO 4406
1-2 0.01 - 0.02 1
2-4 0.02 - 0.04 2
4-8 0.04 - 0.08 3
8-16 0.08 - 0.16 4
16-32 0.16 - 0.32 5
32-64 0.32 - 0.64 6
etc. etc. etc.
4 x 10
3
- 8 x 10
3
40 - 80 13
8 x 10
3
- 16 x 10
3
80 - 160 14
16 x 10
3
- 32 x 10
3
160 - 320 15
32 x 10
3
- 64 x 10
3
320 - 640 16
64 x 10
3
- 130 x 10
3
640 - 1300 17
130 x 10
3
- 250 x 10
3
1300 - 2500 18
250 x 10
3
- 500 x 10
3
2500 - 5000 19
The step to the next cleanliness level means double or half the number of particles.
9 520L0467 Rev GC Feb 2008
The new method counts more smaller
particles and less larger particles.
For better understanding please see the
graph beside. This graph demonstrates
the effect of the change to the new
particle sizes 4 m (c), 6 m (c), and
14 m (c).
Again, the actual number of particles of
a sample is of course the same, only the
counting method is different. Although
it may look like, the new method does
not allow more particles.
(continued)
Measurements with the same uid sample will result in the same cleanliness class for
both methods as shown in the table below.
Number of particles per milliliter, particle count comparison
Together with this ISO 4406 change a new calibration standard ISO 11 171-1999 and
a new Multi-pass test ISO 16 889-1999 for lters have been developed.
0
0
5 10
1000
2000
3000
4000
5000
15 17
Particle size (?m)
N
u
m
b
e
r

o
f

p
a
r
t
i
c
l
e
s

p
e
r

m
l
ISO 4406-1987
ISO 4406-1999
P001 948E
s d r a d n a t s d l O n o i t p i r c s e d t s e T s d r a d n a t s w e N
1 9 9 1 - 2 0 4 4 O S I n o i t a r b i l a c ) C P A ( r e t n u o c e l c i t r a p c i t a m o t u A 9 9 9 1 - 1 7 1 1 1 O S I
7 8 9 1 - 6 0 4 4 O S I e d o c s s e n i l n a e l C 9 9 9 1 - 6 0 4 4 O S I
2 8 9 1 - 2 7 4 5 O S I s r e t l i f r o f t s e t s s a p i t l u M 9 9 9 1 - 9 8 8 6 1 O S I
Comparison between old and new standards
ISO 4406-1999 versus prior cleanliness classes
Comparison between old and new standards
e z i s e l c i t r a P m 1 ) c ( m 4 m 5 ) c ( m 6 ) c ( m 4 1 m 5 1
d e z i d r a d n a t s t o N 0 0 0 4 - - - - -
7 8 9 1 - 6 0 4 4 O S I d l O - - 0 0 0 2 - - 0 8 1
9 9 9 1 - 6 0 4 4 O S I w e N - 0 0 0 4 - 0 0 0 2 0 8 1 -
s s a l c s s e n i l n a e l c 6 0 4 4 O S I 9 1 9 1 8 1 8 1 5 1 5 1
10 520L0467 Rev GC Feb 2008
For charge pressure and return line ltration a suction screen with a mesh width of
100 125 m must be used in the suction line to prevent sudden damage due to large
particles.
Recommendation for lter neness / retaining rates (Beta-ratios)
(continued)
13 m
d = 13 m
Square 78.5 m
2
d = 10 m
Old: New:
P001 935E
New particle size denition
The particle size denition has been changed also. The old standard dened the largest
particle extension as the particle size. The new standard uses the projected square area
and converts this to an equivalent diameter, please see the picture below.
Old versus new particle size denition

78.5 m
2
4
d = = 10 m

ISO 4407 (under revision) species particle counting with a microscope. Only particles
larger 5 m and 15 m are manually counted and specied as /18/13. The is used in
place of the rst scale number, while 18 is allocated to 5 m and 13 to 15 m.
) t i u c r i c n e p o + d e s o l c ( n o i t a r t l i f n o i t c u S
5 4 - 5 3
( 5 7 =
0 1
> ) 2
) t i u c r i c d e s o l c ( n o i t a r t l i f e r u s s e r p e g r a h C
0 2 - 5 1
( 5 7 =
0 1
> ) 0 1
) t i u c r i c n e p o ( n o i t a r t l i f e n i l n r u t e R
l a r e n e g
5 4 - 5 3
( 5 7 =
0 1
> ) 2
s r o t o m d n a s p m u p r a e g r o f
0 2 - 5 1
( 5 7 =
0 1
> ) 0 1
Recommended -ratios
11 520L0467 Rev GC Feb 2008
Fluid cleanliness requirements
To achieve the specied unit life a cleanliness level as shown below must be met. Fluid
samples shall be taken either in the loop or at the entry to the pump, which is typically
the suction line. Fluid cleanliness requirements depends on the product and the
products acceptable continuous or rated pressure limits.
Fluid cleanliness requirements according to product
Product
Required cleanliness class
ISO 4406-1999
Curve in the diagram
on page 12
Steering components with open center 22/20/17 A
Orbital motors 22/20/16 B
Steering components with LS and closed center
21/19/16 C
Proportional spool valves
Axial + radial piston pumps and motors
22/18/13 D
Gear pumps and motors
Cartridge and electrohydraulic valves 18/16/13 E
These cleanliness levels can not be applied for hydraulic uid residing in the component
housing/case or any other cavity after transport.
In general for uid change and new uid top up minimum cleanliness class 23/21/15 and
for rst machine start up at the factory minimum cleanliness 25/22/17 must be met if not
otherwise specied. Exceeding these levels may result in start-up damage.
The before mentioned requirements reect the experience gained from a broad range of
applications. For very high lifetime requirements or contamination sensitive components
(e. g. servo valves) better cleanliness levels are necessary.
TECHNICAL
REQUIREMENTS OF
HYDRAULIC FLUIDS
12 520L0467 Rev GC Feb 2008
TECHNICAL
REQUIREMENTS OF
HYDRAULIC FLUIDS
(continued)
10
100
1000
10 000
100 000
11
12
13
14
15
16
17
18
19
20
21
22
23
1 10 100
N
u
m
b
e
r

o
f

p
a
r
t
i
c
l
e
s

p
e
r

m
l

>

I
n
d
i
c
a
t
e
d

s
i
z
e
I
S
O

c
l
a
s
s

n
u
m
b
e
r
Particle size m (c)
4 14 6
24
25
ISO Solid Contaminant Code per ISO 4406-1999
(Automatic Particle Counter (APC) calibration per ISO 11 171-1999)
1 000 000
26
P001 683E
First machine start up
ISO 25/22/17
Fluid change + top up
ISO 23/21/15
A = ISO 22/20/17
B = ISO 22/20/16
C = ISO 21/19/16
D = ISO 22/18/13
E = ISO 18/16/13
Required uid cleanliness diagram
13 520L0467 Rev GC Feb 2008
The design is explained below taking an SPV 9/075 with a charge pump volume of
17 cm
3
by way of example. A continuous pressure of 240 bar is assumed. Accordingly in
section 3 the cleanliness class 18/13 to ISO 4406 results from curve A.
Design of a lter in the suction line
Examinations have revealed that a lter in the suction line with a
35

45
= 75
at a differential pressure of 0.25 bar achieves the required cleanliness level18/13 under
normal operating conditions. In some applications even better cleanliness levels are
achieved. In order to assure that the cleanliness class is maintained we recommend that
samples of the hydraulic uid be drawn during the running-in time and that the particles
be counted. A certain, constant cleanliness level will emerge during the operating time
(see the illustration below).
Cleanliness level evolving as a function of operating hours for particles larger than
15 m
Selection of an Appropriate Filter and Filtration System
EXAMPLE
CLOSED CIRCUIT
Filter A
Filter B
16
15
14
13
12
11
10
C
l
e
a
n
l
i
n
e
s
s

l
e
v
e
l

(
I
S
O

4
4
0
6
)
1 10 100
P001 320E
Operating hours
An analogous graph can be drawn up for
any particle size. The following reference
can serve as a further guide.
A lter element with a
10
= 2.0 1.5 at
0.25 bar differential pressure (50 % - 33 %
ltration efciency for particles > 10 m)
generally reaches the above mentioned
35

45
= 75 value.
Design of a lter in the charge circuit
We recommend using lter elements with
15

20
= 75 (
10
= 10 corresponding to 90 %
ltration efciency) at the differential pressure occurring in the application. A strainer
with a mesh of 100 m 125 m has to be used to protect the charge pump against
coarse contamination. However the actual ltering work has to be performed by the
lter in the charge circuit.
On the basis of what has been said so far the question arises:
Why is a higher lter neness (-value) necessary in a lter in the charge circuit?
Answer:
The Multi-pass test per ISO 16 889 determines the -values at constant volume ow
and almost constant differential pressure increase. These optimal conditions do not
exist in the charge circuit so that a reduced -value sets in as a result of volume ow
and pressure uctuations. The lter industry and research institutes are in the process
of developing practice-oriented test methods to solve this problem. Furthermore, the
possible level of pressure uctuations is much lower in a suction lter. Moreover in
certain circuits the lter is arranged behind the charge circuit pressure limiting valve, so
that the whole charge pump volume ow does not constantly pass the lter. Related to
the whole charge pump volume ow, an arithmetically lower -value emerges here too.
As already said above for the lter in the suction line, it is recommended that the
cleanliness level actually existing or evolving in the course of time be determined here
too.
14 520L0467 Rev GC Feb 2008
Design of a lter in the suction line
Unlike the situation in the closed circuit, the whole main volume ow is taken from
the tank. That is why these suction lters must be adequately dimensioned in order
to achieve appropriate differential pressures and service lives. On the other hand a
lower lter neness can be selected, since a higher volume ow is available. For further
information, please see next page.
Design of a lter in the return line
In the case of return line lters in open circuits, special attention must be paid to
discontinuous volume ows through working cylinders with differing area ratio. Under
certain circumstances it might therefore be advisable to select a larger lter than would
be necessitated by the suction line alone. In any case a strainer with a mesh size of 100
125 m should be provided in the suction line.
Filtration in circuits with multiple pumps
A machine with several pumps using the same reservoir may use one lter only to save
costs. Every circuit must be protected by a suction strainer with 100 125 m mesh.
This mesh equals theoretically:
100-150
= 75
This term should not be used for a screen. The off-line ltration may feed other functions
and circuits like the steering equipment.
Recommendations for differential pressure (pressure drop) of a new lter element
and -ratios for closed and open circuit
In suction line (closed and open circuit):
Differential pressure: 0.1 bar (clean element) at:
Viscosity: 30 mm
2
/s [141.2 SUS]
Flow: closed circuit: charge pump displacement x rated speed
open circuit: pump displacement x rated speed
-ratio:
35-45
= 75 (
10

2)
In charge line (for closed circuit):
Viscosity: 30 mm
2
/s [141.2 SUS]
Flow: charge pump displacement x rated speed
-ratio:
15-20
= 75 (
10

10)
In return line (only open circuit):
Viscosity: 30 mm
2
/s [141.2 SUS]
Flow: charge pump displacement x rated speed
-ratio: general:
35-45
= 75 (
10

2)
for gear pumps and motors:
15 - 20
= 75 (
10

10)
By-pass ltration
As in charge line.
There will and must be exceptions to these recommendations to ensure an economic
ltration system.
OPEN CIRCUIT
15 520L0467 Rev GC Feb 2008
Dirt absorption capacity, maximum differential pressure
A further criterion for selecting the lter size is the dirt absorption capacity and
differential pressure rise in the case of increasing contamination, see the illustration
below.
When the Multi-pass test to ISO 16 889 is performed, the dirt absorption capacity is also
determined. It is important to distinguish between the apparent dirt absorption capacity,
which is the amount of dirt added during the test, and the real dirt absorption capacity,
which is the amount of dirt actually retained in the lter.
The following equation applies:
Added dirt quantity (apparent dirt absorption capacity) minus dirt quantity
remaining in the oil is the actual dirt absorption capacity.
OPEN CIRCUIT
(continued)
Change filter!
6
4
3
2
D
i
f
f
e
r
e
n
t
i
a
l

p
r
e
s
s
u
r
e

(
b
a
r
)
10 20 30
P001 321E
Dirt Capacity (g)
5
1
In the illustration beside the rise in
the differential pressure starts in an
approximately linear manner before
rising exponentially. Once this zone is
reached it is time to change the lter,
since a little dirt means a large increase
in the differential pressure.
In the case of the above lter element,
the contamination indicator should
respond either optically or electrically
at approximately 2.2 bar and indicate
that it is time to change the elements
concerned.
Rise of the differential pressure when dirt
is added
Depending on the lter material, certain
maximum differential pressures must not
be exceeded since the lter material may
be damaged and dirt already retained
will be released again, i. e. the dirt is
pumped through.
The curve of the -value versus the
differential pressure shows this
(see the illustration beside).
If it is expected that the lter element
will not be changed in time before the
rupture point is achieved, a bypass valve
(see below) must be installed.
A bypass valve must also be provided
if the differential pressure rises to an
inadmissible level during cold starts,
which is usually the case.
Retention rate as a function of the
differential pressure
100
75
50
10
10 20
5
0.5 1 5
10
-
v
a
l
u
e
Differential pressure (bar)
P001 322E
16 520L0467 Rev GC Feb 2008
WHY A BYPASS? Function of a bypass During operation the differential
pressure at the lter element rises due
to contamination. Without a bypass,
especially during cold starts, this would
lead to demage to the lter element or
collapse of the support elements. This
can be effectively prevented by the use
of a bypass.
Although the effective lter efciency
is reduced by the short opening of the
bypass during cold starts, the hydrostatic
unit is not immediately damaged as a
result of this. P001 324E
The cleanliness level simply deteriorates as a function of the time during which the
bypass is in operation and as a function of the newly generated particles. Working with
an open bypass for several hours or days should be avoided. This condition can be
monitored reliably with a contamination indicator (see section Contamination indicator,
page 17). The system operator thus determines the service life of the hydrostatic units
and the rest of the system by regularly checking the contamination level of the lter and
changing the lter elements in time.
It is important to understand that if used as explained above, a bypass is always better
than the sudden release of a particle or a dirt cloud due to damage to an element
whereby the cloud is passed through the whole system (including the high-pressure
circuit) and nally lands in the tank after irreparable damage is sustained by the sliding
parts. If there is no contamination indicator either, this damage is not noticed and it may
be that the system is operated for a long time with this unintentional bypass (after
the element has been destroyed!) until overheating caused by reduced efciency of the
hydrostatic units is recognized. This then turns out to be much more expensive than
the additional bypass and the contamination indicator would have been (see section
Contamination indicator, page 17).
A bypass should be arranged as shown above or even further away from the element if
the design allows this. Under certain circumstances it may even be a design advantage
if the lter elements are to be bolted directly on to the pump (charge circuit ltration). A
bypass may never be situated in the base of the lter element since the dirt settles in this
area and is ushed into the system again.
17 520L0467 Rev GC Feb 2008
CONTAMINATION
INDICATOR
AIR BREATHER
The contamination indicator responds when a predetermined differential pressure
occurs as a result of growing contamination of the lter element. An optical signal
appears, or an electrical contact is energized.
Function of the contamination indicator (differential pressure)
1. Pressure before the lter element
2. Pressure behind the lter element
3. Position of the magnets in a clean
element
4. Position of the magnets in a
contaminated element
P001 323
Sufcient attention must also be devoted to air breathers, since a considerable portion
of the contamination makes its way into hydraulic systems via unsuitable ventilation
systems. Design measures such as pressurizing reservoirs are often not economically
efcient by comparison with todays air breathers. Under certain circumstances it may
be necessary to observe the Pressurized Container Regulations if the pressure content
product derived from tank volume times pressure exceeds a certain value.
Unfortunately there is no standard for air breathers corresponding to the Multi-pass test
to ISO 16 889. The lter neness quoted by the manufacturer of the air breathers has to
be relied on. This does not permit comparisons between manufacturers A and B since, as
already mentioned, there are no standardized tests. Generally speaking the neness of
the air breathers must be equivalent to or better than the working lters present in the
system. Therefore only the
x
= 75 values and the given lter neness of the air breathers
can be taken as standard values.
18 520L0467 Rev GC Feb 2008
As a brief reminder:
It was explained before that the cleanliness level is inuenced by:
the -value (lter neness, ltration ratio)
the volume ow through the lter
If the required cleanliness level is not achieved using the 17 cm
3
/U charge pump and
the
10
= 75 lter, it is not necessarily expedient to use a larger charge pump. This may
necessitate a larger lter since the differential pressure more quickly reaches the limit
of p = 0.25 bar (risk of cavitation) with a clean lter element, which leads to insufcient
service life of the element. The energy balance also deteriorates as a result of the higher
power loss.
In this case lters with a higher -value must be used. However, since the higher -values
generally also involve higher differential pressures, it is often also necessary to move
the lter to the charge circuit. If the lter elements are designed accordingly, higher
differential pressures are admissible here so that the overall dimensions of the lter
can be reduced - representing an installation advantage. It must also be claried and
checked to what extent new contamination can be reduced and prevented.
It was explained before that inadequate ventilation facilities are a cause of fresh
contamination. An improvement of the cleanliness level can often be achieved by using
ventilation lters with better lter neness, especially for applications with working
cylinders with differing area ratios.
For the design of the ventilation lter the differential pressure (caused by the differential
air volume ow) must be kept as low as possible in order to prevent cavitation in the
suction area of the pumps. It should also be checked whether unsuitable piston rod seals
or leaks are the cause.
Remember:
Dirt which does not enter the system or is not caused by wear need not be removed by
ltration.
Filtration is intended to remove contamination from the hydraulic uid. For this, however,
the contamination must be passed to the lter element. In a closed circuit without circuit
purging, existing contamination can only be removed from the system with the oil
leaking from the pistons, the control valve etc. Since only particles smaller than the leak
gap width can leave the closed circuit, the remaining particles stay in the circuit and can
lead to erosion damage in areas with high ow velocities.
This can be avoided by circuit purging, i. e. by forcing 56 l/min from the low pressure
circuit via an spool valve and a purge relief valve.
The contamination ushed out in this way (including particles larger than the leak gap
width) can now be passed to the lter element installed in the system and be removed.
WHAT IS TO BE DONE
IF THE REQUIRED
CLEANLINESS CLASS IS
NOT ACHIEVED?
WHY LOOP FLUSHING?
19 520L0467 Rev GC Feb 2008
Taking of Fluid Samples
Fluid samples must be drawn very carefully into appropriate bottles to prevent
extraneous dirt from, falsifying the sample result.
The sample bottle should contain a label with the following information:
Sample number
Source of sample
Sampling method
Date and time of sampling
Nature of uid
Comments/remarks if necessary
Sampling points should be provided at the design stage of the hydraulic installation.
They should be arranged in the turbulent main ow.
Sampling device
Important: Take precautionary measures to protect personnel and equipment.
If turbulent ow conditions prevail in the main ow, a typical sampling device as
illustrated in the illustration P001 325, page 20
A quick fastening coupling 6 is permanently attached to the opening through which
the sample is to be withdrawn
A dust protection cap 1 is provided for the part 6
The remaining part of the unit 2-5 is secured for sampling
The inner diameter and length of the capillary tube are selected in agreement with
the desired sample quantity
Capillary tubes with an inner diameter of less than 1.25 mm may not be used. Other
cross-sectional forms (e. g. rectangular) can be used, provided that the smallest
internal dimension is not less than 1 mm
The end of the capillary tube is sharpened and deburred in order to facilitate the
subsequent penetration of the lm which covers the opening of the sample bottles
If no turbulence can be guaranteed in the ow, a device for generating turbulence
must be used, e. g. a turbulent sampler
Sampling method
Ball valve 5 is opened
Allow at least 200 ml uid to ow through the sampling device before collecting the
uid
Without closing the ball valve, place the sample bottle in the position for collecting
the uid
Pierce the protective lm covering the bottle opening with the sharp end of the
capillary tube
Draw a sample of not more than 90 % and not less than 50 % of the bottle volume.
When a sufcient sample quantity has been collected, remove the sample bottle
before stopping the ow with the ball valve
Seal the sample bottle immediately after withdrawing the capillary tube
If a sampling device with quick-fastening coupling is used, the removable parts
of the sampling device are to be dismantled and all other uid traces are to be
removed by ushing with a suitable solvent
Immediately after dismantling the dust protection cap is replaced on the
permanently mounted part of the quick fastening coupling.
TAKING OF FLUID
SAMPLES
SAMPLING ACCORDING
TO ISO 4021 FROM
A SYSTEM IN OPERATION
20 520L0467 Rev GC Feb 2008
Taking of Fluid Samples
Typical sampling device in practice SAMPLING ACCORDING
TO ISO 4021 FROM
A SYSTEM IN OPERATION
(continued)
Sampling from a tank according to CETOP RP 95 H
Sampling from the tank should only be carried out if it is not possible to sample from the
main ow.
Clean the outer surface of the tank around the places from which the sample is to be
drawn.
Sampling:
The uid in the tank should be mixed well in order to ensure that the sample is typical.
To this end warm up the system by running it under operating conditions. Then draw a
sample (at least 150 ml) with the aid of a pipette or a cleaned disposable syringe. Pass
the pipette about half way down into the uid.
Ensure that the pipette does not touch the side walls of the tank or come too close to
the bottom. Fill the contents of the pipette into the sample bottle and seal this carefully.
Cover the tank again or close it with clean covering lm if further samples are required.
P001 325
1. Dust protection cap
2. Valve without check device
3. Capillary tube for drawing off uid
4. Cover cap with capillary tube
5. Ball valve
6. Check valve, outer part for quick
fastening
21 520L0467 Rev GC Feb 2008
The frequency and intensity of the maintenance work to be performed depend on the
burden generated by environmental inuences and on the workload.
Special attention must always be paid to the operational suitability and cleanness of the
hydraulic uid.
Scavenging and running in
Before a hydraulic system is commissioned, the assembly dirt must be removed. This
is best done by ushing the whole installation with a portable lter unit. Mineral oil
(or another medium compatible with the hydraulic uid to be used subsequently) is
pumped through the whole system or parts of the system at the highest possible ow
velocity. The assembly dirt is ltered in the lter unit.
During this process the elements of the built-in lters are to be removed. Small or less
sensitive systems can also be scavenged with the built-in lters during the running-in
process. It must be ensured that the system is run without load but with a displacement
which is gradually increased up to maximum. The illustration below shows the relation
between the design-specic, admissible cleanliness level and the actual cleanliness prior
to commissioning.
Working Hints
WORKING HINTS
Typical relation between the design-
specic, admissible cleanliness level A
and the actual cleanliness level prior to
commissioning D.
It is vital that the system be ushed and
run at low pressure until the required
cleanliness level is achieved.
P
a
r
t
i
c
l
e

c
o
u
n
t

p
e
r

u
n
i
t

v
o
l
u
m
e
Particle size in m (log
2
)
10
2
10 15 50 25 100
P001 326E
5
10
3
10
4
10
5
10
6
D
A
22 520L0467 Rev GC Feb 2008
Permanent
Every lter should be equipped with an optical/electrical indicator of the contamination
level at the lter. In this way it is possible to establish at any time whether there is still any
dirt absorption capacity or whether the elements have to be changed. The checks should
be carried out daily once the operating temperature is achieved.
If a contamination indicator with electrical signal device is used, the selected signal is
emitted at operating temperature when the lter element is contaminated. During the
warming up phase a contaminated signal is nearly always emitted due to the higher
differential pressure unless the contamination indicator is equipped with a signal cut-out
for the cold start phase.
Cyclical
With regular monitoring, lters are suitable as wear surveillance elements for the
components of the hydraulic system. If the operator keeps a log of lter changes, it
can be assumed in the event of shorter changing intervals that the wear of the system
components is increasing. The origin of the main contamination can be ascertained by
analysing a uid sample and the contaminated element. A comparison of the results with
the materials used allows preventive maintenance before a complete failure interrupts
production or operation. Adherence to the required cleanliness level is checked by
measuring the contamination and this ensures that no premature wear or failure occurs.
These samples must be drawn at specially designed sampling points as explained before.
Topping up hydraulic uid
Any uid used to top up losses should always be poured in via a ne lter in order to
maintain the cleanliness class. Where appropriate facilities are available, the return ow
lter can be used. It is advisable to provide a permanent connection which should be
included in considerations at the design stage. Any opening of the tank/reservoir for
maintenance purposes (topping up hydraulic uid, sampling, changing lter elements in
built-in tanks etc.) should always be avoided as far as possible by an expedient design.
Even though some ventilation lters have a so-called lling screen (mesh width >
100 m), this still does not afford any protection against the penetration of particles of
the order of magnitude of 10 100 m.
MONITORING
OF CONTAMINATION
Working Hints
23 520L0467 Rev GC Feb 2008
Changing the element
If the contamination indicator shows a contaminated element, this must be changed
without delay due to the high rate of increase of pressure drop as the element becomes
more contaminated. Extreme care must be taken when changing the element.
The operating instructions must be followed precisely.
The following standard values apply for lter maintenance intervals:
1. 24 hours after commissioning the system
2. After the running-in period (50 - 100 hours of service)
3 Normal maintenance after 300 - 500 hours of service
Literature:
1. Guidelines to Contamination Control in Hydraulic Fluid Power Systems (1985),
AHEM (The Association of Hydraulic Equipment Manufacturers, London)
2. Filterbel fr Hydraulikssigkeiten und Schmierstoffe,
MAHLE Industrielter, hringen
3. Leitfaden zur Optimalen Auswahl von Argo Filtertypen fr Hydrauliksysteme,
ARGO Filter, Kraichtal-Menzingen.
Figure and text source: 9, 17, 18, 20, 21, 22, 23 MAHLE Industrielter
MONITORING
OF CONTAMINATION
(continued)
Working Hints
Sauer-Danfoss Hydraulic Power Systems
Market Leaders Worldwide
Sauer-Danfoss is a comprehensive supplier providing complete
systems to the global mobile market.
Sauer-Danfoss serves markets such as agriculture, construction, road
building, material handling, municipal, forestry, turf care, and many
others.
We offer our customers optimum solutions for their needs and
develop new products and systems in close cooperation and
partnership with them.
Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
total system design.
Sauer-Danfoss provides comprehensive worldwide service for its
products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
Sauer-Danfoss (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sauer-Danfoss (Neumnster) GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone +49 4321 871-0, Fax: +49 4321 871 122
Sauer-Danfoss (Nordborg) ApS
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
www.sauer-danfoss.com
OUR PRODUCTS
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Joysticks and control handles
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520L0467 Rev GC Feb 2008

Design Guideline For Hydraulic Fluid Cleanliness

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2 520L0467 Rev GC Feb 2008

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